The course is divided into modules. Each module will build on the previous one so that learning is done in an organized and structured format. An overview of each module is as follows:
Day 1: Alarm Management Concepts and Tools
Module 1: Introduction - The workshop begins by describing key issues surrounding "the alarm management problem." You will be given context regarding the many facets of Alarm Management as well as a description of the course objectives.
Module 2: Standards Legislation - This module reviews key legislation regulating alarm management and how it affects your facility. Upon completion of this module you will understand the key differences between EEMUA 191 and ISA SP18.2 enabling you to make informed business and operational decisions about your facility.
Module 3: Alarm Management Concepts & Tools - In this module you will learn about the different types/phases of Alarm Management and methods therein. Upon completion of this module you will:
- Understand the different types of Alarm Management efforts
- Understand the tools required to achieve Alarm Management Goals
- Know the components of an effective Alarm Management System
Module 4: Philosophy Document - Companies spend several months and several thousands of dollars on consultants to develop a site-specific alarm philosophy document. This module teaches you how to develop your own philosophy document tailored to your plant and control system. After reviewing the key sections of an alarm philosophy, you will develop your own specific document. Upon completing this module, you will:
- Learn what an alarm is, and the purpose of the alarm system
- Understand guiding rules and available options for determining alarm settings
- Know what to avoid when building your alarm philosophy
- Understand performance goals and continuous monitoring
- Understand Alarm design: Purpose, Priority definitions, Alarm Groups, Alarm Interface, Alarm options (Analog, digital, deviation, logic, etc)
- Know the significance of management-of-change and notification
- Understand roles and responsibilities
The module also provides additional information on what alarm system information should be contained in a functional specification.
Module 5: Control System Lifecycle and Strategic Planning - This module explains the importance of control systems reliability, how to benchmark your system, and the impact on operator workload and alarm rates. The module then provides a framework on how to prepare a strategic plan to improve the ongoing performance of your systems.
Module 6: Alarm Management Assessment - This module teaches you how to assess and measure the effectiveness of your site alarm management activities. A review of the tools, practices, and benchmarks are presented to help put a framework together for each participant to analyze and assess their own site.
Module 7: Alarm Analysis - Benchmark and analyse your current system to determine what alarms are giving you problems, which alarms can be easily fixed and the areas of quick returns. You will develop and determine key alarm performance metrics that you can continuously rely on to give a constant indication of the state of your alarm system. These metrics will be revisited throughout the life cycle to ensure that your process is operating at an optimal level with respect to alarming. You will:
- Understand alarm history collection considerations
- Learn how to set up an alarm history system
- Know how to analyse alarm history according to EEMUA/ISA standards
- Learn how to benchmark your system to know your current state and which areas require attention in order to reach the goals decided in your philosophy
- Know how to follow-up on the analysis
Day 2: Advanced Alarm Management, Analysis and Rationalization
Module 8: Alarm Design, Rationalization and AOA meetings – Systematic alarm design for new plant and alarm rationalisation are procedures where each alarm is examined to ensure it conforms to the alarm philosophy. Participants will learn the full processes, which include:
- Systematically analyzing and fixing alarm systems to further reduce alarms
- Setting up a master database to store rationalisation efforts
- Learning the design and rationalisation meeting structure
- Rationalisation/design exercises
Module 9: Ongoing Maintenance Techniques - Once your alarm system has improved, it is vital to maintain it so as not to lose the results and the value realised. This module will provide and review the best practices in industry for simplifying monitoring and maintenance activities and leveraging your alarm management infrastructure.
Module 10: Control Room Design and Graphic Display Standards – Modern building practices, ergonomic studies, extended work hours, high resolution displays, and alarm rates are all factors that need to be considered in determining the ideal environment for your operators. This module gives an overview of the new standards and how to improve operator efficiency.
Module 11: State-Based Alarming – This module gives a detailed overview of how and when to implement state-based alarm solutions. Various different scenarios are discussed and participants get to develop their own solution using the simulation software.
Module 12: Model-Based Alarming – This module provides participants with a detailed overview of the theory of model based alarming. Participants will also learn when to use this advanced technique, how to build a model, and what tools are available.
Module 13: Predictive Alarming – This module teaches how to take a properly integrated alarm philosophy and expand it to equipment monitoring to prevent and reduce downtime as well as optimize plant production. The module looks at how alarm systems are also critical for plant maintenance personnel. For example, how would you effectively integrate online monitoring and equipment condition assessment for key generation equipment including turbines, pumps, fans, coal mills, pulverizers, precipitators and others into your alarm system?
Module 14: Other Advanced Alarm Techniques – This module provides an overview of other advanced alarm techniques such as auto alarm suppression, using techniques such as Six SIGMA and 5S, and alarm notification/escalation.